Modular rack system

ABSTRACT

A modular rack for holding workpieces includes a plurality of modules. The modules can include at least one base member, a first module having a horizontal workpiece support member, at least one structural support member, and a first connection mechanism, and a second module including a horizontal workpiece support member, at least one structural support member, and a second connection mechanism. The first connection mechanism and the second connection mechanism are engagable with one another to connect the first module to the second module to provide a selectively adjustable, multi-level workpiece support.

FIELD OF THE INVENTION

[0001] The invention relates to modular racks for holding workpieces.

BACKGROUND OF THE INVENTION

[0002] During complex processes such as home construction, it isfrequently necessary to perform an incremental procedure on a workpiece,then set the workpiece aside for a predetermined time. A prime exampleis in the painting of trim pieces, which are typically painted on-site,then set aside while drying. One complication in this practice is thatconstruction sites usually lack suitable space for setting asideworkpieces while drying.

[0003] Racks are known for a variety of purposes. For example, U.S. Pat.No. 5,660,637 to Dodge sets forth a paint rack for use in a vehicle bodyshop including a frame mounted on wheels, which are repositionablewheels for use or storage as desired. The frame may be fixed oradjustable, both vertically and horizontally.

[0004] U.S. Pat. No. 5,607,069 to Stroobants is directed to a rackassembly for use in supporting articles for processing, cleaning,painting and paint stripping, the rack assembly being comprised ofmodular components which can be conveniently assembled. The modularcomponents can be assembled in various patterns depending on the shapeof the articles to be painted and can be conveniently and compactlystored when not in use.

[0005] U.S. Pat. No. 6,338,758 to Curran deals with a multiple doorpaint rack system for consolidating doors and shutters for spraypainting and storing in an organized assembly. The system includes anelongated base member, a first support member secured vertically to oneend of the base member, a second support member secured vertically tothe opposite end, a cross beam slidably secured between the supportmembers by an adjustable securing pin vertically adjustable, and asliding swivel support assembly slidably secured to the elongated basemember and the cross beam.

[0006] Another example is set forth in U.S. Pat. No. 4,934,015 to Mink,directed to a mini-blind cleaning rack wherein a downwardly extending“U” shaped frame is provided, including a plurality of telescopingmembers defining the legs and base of the “U” shaped member. Theterminal ends of the legs are further provided with positioning feetslidingly receiving extension legs for effecting stability of theorganization. A plurality of upwardly directed clamps are slidably andadjustably positionable upon the overlying base of the “U” shapedframework with a second pair of clamps slidably and fixedly securableand downwardly directed mounted to a cross-bar adjustably positionableupon the spaced parallel legs of the “U” shaped framework. The unitaccordingly accommodates and extends a mini-blind work piece between thepairs of clamps wherein the clamps may be extended to accommodatevarying lengths and positioned upon the respective base and cross-bar ofthe apparatus to accommodate varying widths of mini-blinds.

[0007] Although these arrangements offer some advantages over simplyleaning workpieces against a wall, they are complex and relativelyexpensive. It can be seen from the foregoing that the need exists for asimple, inexpensive modular rack system that provides fabrication andinstallation advantages, overcoming the deficiencies of knownarrangements.

SUMMARY OF THE INVENTION

[0008] These and other objects are achieved by providing a modular rackfor holding workpieces including a first module having a horizontalworkpiece support member, at least one structural support member, and afirst connection mechanism. A second module includes a horizontalworkpiece support member, at least one structural support member, and asecond connection mechanism. The first connection mechanism and thesecond connection mechanism are engagable with one another to connectthe first module to the second module to provide a selectivelyadjustable, multi-level workpiece support.

[0009] The features of the invention believed to be patentable are setforth with particularity in the appended claims. The invention itself,however, both as to organization and method of operation, together withfurther objects and advantages thereof, may best be understood byreference to the following description, taken in conjunction with thefollowing drawings.

DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a schematic perspective view of a modular rack systemincorporating the principles of the present invention.

[0011]FIG. 2 is an exploded schematic perspective view of a modular rackincorporating the principles of the present invention.

[0012]FIG. 3 is a schematic cross-sectional view of a support memberforming part of a modular rack incorporating the principles of thepresent invention.

[0013]FIG. 4 is a schematic cross-sectional view of a support memberforming part of a modular rack incorporating the principles of thepresent invention.

[0014]FIG. 5 is a schematic cross-sectional view of a support memberforming part of a modular rack incorporating the principles of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

[0015]FIG. 1 illustrates an embodiment of a modular rack system 10 inaccordance with the principles of the present invention. The rack system10 includes a first support unit made up of a first module 12, a secondmodule 14, and a third module 16. A second support unit of the racksystem 10 includes a first module 18, a second module 20, and a thirdmodule 22. The support units are constructed to support workpieces W1,W2, and W3.

[0016] The first module 12 includes a pair of base members having avertical upright portion 12 a secured to a horizontal base portion 12 b.The base members 12 b form a base for the base members to be placed on afloor or other horizontal support surface. The base members are shown asbeing mounted interior of the vertical upright portion, but it is alsocontemplated that the base members can be reversed to place thehorizontal base portion exterior of the vertical upright portion towiden the footprint of the rack system. Casters C or other rollingmechanisms can be provided to enhance the mobility of the rack system.The second module 14 includes a horizontal workpiece support member 14 asupported between a pair of structural support members 14 b, 14 c. Thethird module 16 includes a horizontal workpiece support member 16 asupported between a pair of structural support members 16 b, 16 c. Thehorizontal workpiece support members can be provided with a telescopingwidth adjustment with detents as shown, constructed as such mechanismsare known per se. The second support unit includes modules 18, 20, and22 configured similarly to modules 12, 14, and 16.

[0017] As shown in FIG. 2, the modules 12, 14, 16 include connectionmechanisms. When the support members are fabricated from annular tubularmaterial, the connection mechanisms can be configured as extensions 24,26 coming out of the respective modules 14, 16. The extensions 24, 26have exterior cross-sections designed to fit within inner cross-sectionsof adjacent structural support members as shown. Supplemental supportbars B can be provided to afford additional structural rigidity to therack system 10. The support bars B are at least long enough to extendthrough each of the modules 12, 14, and 16, and have an externalcross-section selected to slide into and through the interiorcross-sections of the extensions 24, 26.

[0018] The first horizontal workpiece support member can be secured tothe first horizontal workpiece support member at a first verticaldistance V1 from an end of the pair of first structural support members.The second horizontal workpiece support member is secured at a secondvertical distance V2 from an end of the pair of second structuralsupport members. If it is desirable for a particular application, thefirst vertical distance V1 can be different from the second verticaldistance V2 in order to provide selectively adjustable, multi-levelworkpiece supports.

[0019] The workpiece support members and structural support members canbe provided with a variety of cross-sections, circular or polygonal. Themodules shown in FIGS. 1 and 2 have generally square cross-section. FIG.3 shows a generally circular cross-section, while FIGS. 4 and 5 showpolygonal cross-sections, triangular and octagonal, respectively. Thesystem 10 can be fabricated from any suitable material, depending inlarge part upon the intended use of the system. If heavy workpieces suchas doors are contemplated, extruded tubular aluminum or tube steel aresuitable material choices, while a plastic material such as extrudedthermoplastic or PVC could be used for lighter workpiece applicationssuch as light trim. The cross-sectional size of the support members willdepend upon the material chosen, taking into consideration manufacturingconsiderations and the specific rack application.

[0020] The present invention permits a wide range of adjustability to adrying rack system. Varying heights can be accommodated by selection ofhorizontal workpiece support location. Varying widths can beaccommodated by providing the horizontal workpiece supports withtelescoping width adjustments. The modules can be provided withcolor-coding or other indicia to make height coordination simple. Anyvolume of workpieces can be dealt with by providing as many modules asnecessary. The modules are simply and easily assembled by slip-fittinginto one another.

[0021] Although the present invention has been described with referenceto specific embodiments, those of skill in the art will recognize thatchanges may be made thereto without departing from the scope and spiritof the invention as defined by the appended claims.

What is claimed is:
 1. A modular rack for holding workpieces, the rack comprising the following: at least one base member; a first module including a horizontal Workpiece support member, at least one structural support member, and a first connection mechanism; and a second module including a second horizontal workpiece support member, at least one structural support member, and a second connection mechanism; whereby the first connection mechanism and the second connection mechanism are engagable with one another to connect the first module to the second module to provide a selectively adjustable, multi-level workpiece supports.
 2. A modular rack in accordance with claim 1, wherein the structural support members comprise pairs of vertically oriented, parallel rigid support members located at opposite ends of the respective horizontal workpiece support members.
 3. A modular rack in accordance with claim 2, wherein the structural support members are fabricated from annular tubular material having an interior cross-section.
 4. A modular rack in accordance with claim 3, wherein the first connection mechanism comprise extensions from the structural support members, the extensions having a cross section adapted to fit within the interior cross-section of the structural support members.
 5. A modular rack in accordance with claim 2, wherein the structural support members have a generally square cross-section.
 6. A modular rack in accordance with claim 2, wherein the structural support members have a generally round cross-section.
 7. A modular rack in accordance with claim 2, wherein the structural support members have a polygonal cross-section.
 8. A modular rack in accordance with claim 7, wherein the structural support members have a generally octagonal cross-section.
 9. A modular rack in accordance with claim 2, wherein the structural support members are fabricated from a metallic material.
 10. A modular rack in accordance with claim 9, wherein the structural support members are fabricated from aluminum.
 11. A modular rack in accordance with claim 2, wherein the structural support members are fabricated from a plastic material.
 12. A modular rack for holding workpieces, the rack comprising the following: at least one base member; a first module including a first horizontal workpiece support member, a pair of first structural support members secured to opposite ends of the first horizontal workpiece support member, and a first connection mechanism, the first horizontal workpiece support member being secured to the first horizontal workpiece support member at a first vertical distance from an end of the pair of first structural support members; and a second module including a second horizontal workpiece support member, a pair of second structural support members secured to opposite ends of the second horizontal workpiece support member, and a second connection mechanism, the second horizontal workpiece support member being secured to the second horizontal workpiece support member at a second vertical distance from an end of the pair of second structural support members, the second vertical distance being different from the first vertical distance; whereby the first connection mechanism and the second connection mechanism are engagable with one another to connect the first module to the second module to provide a selectively adjustable, multi-level workpiece support.
 13. A modular rack in accordance with claim 12, wherein the first and second structural support members are fabricated from annular tubular material having an interior cross-section.
 14. A modular rack in accordance with claim 13, wherein the first connection mechanism comprise extensions from the first structural support members, the extensions having a cross section adapted to fit Within the interior cross-section of the structural support members.
 15. A modular rack in accordance with claim 12, wherein the structural support members have cross-section selected from a group consisting of generally square, round, and octagonal.
 16. A modular rack in accordance with claim 12, wherein the structural support members are fabricated from a metallic material.
 17. A modular rack in accordance with claim 16, wherein the structural support members are fabricated from aluminum.
 18. A modular rack in accordance with claim 12, wherein the structural support members are fabricated from a plastic material.
 19. A method of assembling a modular rack for holding workpieces, the method comprising the following steps: providing at least one base member; providing a first module including a first horizontal workpiece support member, a pair of first structural support members secured to opposite ends of the first horizontal workpiece support member via a first connection mechanism; providing a second module including a second horizontal workpiece support member, a pair of second structural support members secured to opposite ends of the second horizontal workpiece support member via a second connection mechanism; and engaging the first connection mechanism with the second connection mechanism to connect the first module to the second module to provide a selectively adjustable, multi-level workpiece support.
 20. A method in accordance with claim 19, wherein the steps of providing first and second modules comprise securing the first horizontal workpiece support member to the first horizontal workpiece support member at a first vertical distance from an end of the pair of first structural support members, and securing the second horizontal workpiece support member to the second horizontal workpiece support member at a second vertical distance from an end of the pair of second structural support members, the second vertical distance being different from the first vertical distance. 